Owner’s Guide€¦ · WELCOME Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Guide. This guide contains

622022

Owner’s Guide

ISSUED JULY 2011 REVISED SEPTEMBER 2013

WELCOME

Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Guide. This guide contains the information that will assist you in maintaining this highly reliable vehicle. Some illustrations may show items that are optional for your vehicle. This guide covers the operation of several vehi-cles; therefore, some illustrations may not represent your vehicle. Physical differences in controls will be illustrated.Most of the service procedures in this guide can be accomplished using common, automotive hand tools. Contact your service representative on servicing the vehicle in accordance with the Periodic Service Schedule.Repair or replacement parts are available through your E-Z-GO retailer or E-Z-GO Genuine Service Parts.

The following information is needed when contacting E-Z-GO concerning service or parts for your vehicle:

Vehicle Model ____________________________________________________________________________

SERIAL Number / PIN Number / VIN Number __________________________________________________

FOREWORDRead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

OWNER’S GUIDEGASOLINE POWERED VEHICLE

TERRAIN 500TERRAIN 1000

EXPRESS S4EXPRESS L4

STARTING MODEL YEAR 2012Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specifications. Such modifications can cause serious personal injury or death. E-Z-GO Division of Textron, Inc. pro-hibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehi-cle.E-Z-GO Division of Textron, Inc. reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold previously.The information contained in this manual may be revised periodically by E-Z-GO Division of Textron, Inc., and therefore is subject to change without notice.E-Z-GO Division of Textron, Inc. DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.These are the original instructions as defined by 2006/42/EC.

TO CONTACT US

E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Road.Augusta, Georgia, USA 30906-3852

North America:Technical Assistance & Warranty PHONE: 1-800-774-3946 FAX: 1-800-448-8124Service Parts PHONE: 1-888-GET-EZGO (1-888-438-3946) FAX: 1-800-752-6175International:PHONE: 001-706-798-4311 FAX: 001-706-771-4609

Page i

FOREWORDRead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in

the USA unless otherwise indicated.

The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

Overfilling battery may void the warranty.

Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty.

When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State

emission certification applicable at the time of manufacture.

BATTERY PROLONGED STORAGE

All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75°F (-60°C).

BATTERY DISPOSAL

Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant

containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state

environmental officials regarding disposal information.

Page ii

TABLE OF CONTENTSRead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

SECTION PAGE NO.

SAFETY............................................................................................................................................................................... 1-1

GENERAL SPECIFICATIONS............................................................................................................................................. 2-1

INTRODUCTION.................................................................................................................................................................. 3-1

OPERATING PROCEDURES.............................................................................................................................................. 4-1

MAINTENANCE................................................................................................................................................................... 5-1

DELCARATION OF CONFORMITY ................................................................................................................ APPENDIX A-1

Page iii

TABLE OF CONTENTSRead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

Notes:

Page iv

SAFETYRead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

1
TITLE PAGE NO.
SAFETY................................................................................................................................................................. 1-3

NOTICES, CAUTIONS, WARNINGS, AND DANGERS......................................................................................... 1-3

GENERAL ............................................................................................................................................................. 1-5

GENERAL OPERATION ....................................................................................................................................... 1-5

MAINTENANCE .................................................................................................................................................... 1-6

VENTILATION ....................................................................................................................................................... 1-6

LABELS AND PICTOGRAMS ............................................................................................................................... 1-7

1 - 1


1
Notes:
1 - 2


1SAFETYFor any questions on material contained in this manual, contact an authorized representative for clarification.Read and understand all labels located on the vehicle. Always replace any damaged or missing labels.On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre-vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered abuse and will not be covered under warranty.Use extra caution when towing the vehicle(s). Do not tow a single vehicle at speeds in excess of 12 mph (19 kph). Do not tow more than three vehicles at a time. Do not exceed 5 mph (8 kph) while towing multiple vehicles. Towing the vehicle at above the recommended speed may result in personal injury and/or damage to the vehicle and other property. Vehicles equipped with the AC Drive motor must be towed with the Run-Tow switch, located under the pas-senger seat, in the ‘Tow’ position.If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.

Observe these NOTICES, CAUTIONS, WARNINGS and DANGERS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe.

NOTICES, CAUTIONS, WARNINGS, AND DANGERSThroughout this guide NOTICE, CAUTION, WARNING, and DANGER will be used. Please observe these NOTICES, CAUTIONS, WARNINGS, and DANGERS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe.

Address practices not related to personal injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WASH HANDSAFTER HANDLING!

Battery posts,terminals and relatedaccessories contain

lead and lead compounds,chemicals known

to cause cancer andreproductive harm.

BATTERY WARNING

WASH HANDSAFTER HANDLING!

WARNING: Battery posts, terminals and relatedaccessories contain lead and lead compounds,

chemicals known to cause cancer and reproductive harm.

BATTERIESCONTAIN LEAD

AND RELATED PARTS

!

< 14° 25%DO NOT

DRIVE ACROSSSLOPES IN

EXCESS OF 14˚

NOTICE

DANGER

1 - 3


1
Engine exhaust from this product contains chemicals known, in certain quantities, to
cause cancer, birth defects, or other reproductive harm.

The exhaust emissions of this vehicles’ engine complies with regulations set forth by the Environmental Protection Agency (EPA) of the United States of America (USA) at time of manufacture. Significant fines could result from modifi-

cations or tampering with the engine, fuel, ignition or air intake systems

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

This spark ignition system meets all requirements of the Canadian Interference-Causing Equipment Regulations.

This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury or property damage, the following must be carefully observed:

Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-Z-GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z-GO-manufactured vehicle is modified in any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER FEDERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applicable in the places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.

E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.The Company recommends that all E-Z-GO products sold as personal transportation vehicles BE OPERATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE REQUIRE-MENTS. This restriction is important to the SAFE USE AND OPERATION of the product. All customers should adhere to this SAFETY RESTRICTION, in connection with the use of all E-Z-GO products, new and used, the Distributor or Dealer has reason to believe may be operated in personal transportation applications.Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or through the Internet at the web site for the U.S. Department of Transportation - at Dockets and Regulation, then to Title 49 of the Code of Federal Regulations (Transportation)

NOTICE

NOTICE

1 - 4


1
GENERALAll vehicles can be used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible to anticipate and warn against every possible combination of circumstances that may occur. No warning can take replace good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined. E-Z-GO strongly suggests that all users and maintenance personnel read this entire man-ual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.

If you have any questions regarding this vehicle, contact your E-Z-GO dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.

E-Z-GO reserves the right to make design changes without obligation to make these changes on units previously sold. The information contained in this manual is subject to change without notice.

E-Z-GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL. E-Z-GO IS NOT LIABLE FOR INCIDENTAL OR CONSE-QUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL.

This vehicle conforms to the current applicable standard(s) for safety and performance requirements.

These vehicles are designed and manufactured for off-road use. They DO NOT conform to Federal Motor Vehicle Safety Standards of the United States of America (USA) and are not equipped for operation on public streets. Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances.

With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post. Never use the chassis or body as a ground connection.

Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed or extend the stopping distance beyond the factory specification. Such modifications can result in serious personal injury or death.

Do not make any such modifications or changes. E-Z-GO prohibits and disclaims responsibility for all such modifica-tions or and alterations which would adversely affect the safety of the vehicle.

Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions, terrain and common sense.

Operation of the vehicle is limited to persons above the height of 59 inches (150 cm).

GENERAL OPERATIONALWAYS:

• use the vehicle in a responsible manner and maintain the vehicle in safe operating condition• read and observe all warnings and operation instruction labels affixed to the vehicle• follow all safety rules established in the area where the vehicle is being operated• Leave the vehicle when there is a risk of lightning• reduce speed to compensate for poor terrain or conditions

1 - 5


1
• apply service brake to control speed on steep grades• maintain adequate distance between vehicles. • reduce speed in wet areas• use extreme caution when approaching sharp or blind turns• use extreme caution when driving over loose terrain• use extreme caution in areas where pedestrians are present
MAINTENANCEALWAYS:

• replace damaged or missing warning, caution or information labels• maintain the vehicle in accordance with the manufacturer’s periodic service schedule• ensure that repairs are performed by trained and qualified personnel• follow the manufacturer’s maintenance procedures• insulate any tools used within the battery area in order to prevent sparks or battery explosion• check the polarity of each battery terminal and be sure to rewire the batteries correctly• use specified replacement parts, NEVER use replacement parts of lesser quality• use recommended tools• determine that tools and procedures not specifically recommended by the manufacturer will not compromise the

safety of personnel nor jeopardize the safe operation of the vehicle• support the vehicle using wheel chocks and jack stands, NEVER get under a vehicle that is supported by a jack,

lift the vehicle in accordance with the manufacturer’s instructions• maintain the vehicle in an area away from exposed flame or persons who are smoking• be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated• test drive the vehicle after any repairs or maintenance in a safe area that is free of both vehicular and pedestrian

traffic• keep complete records of the maintenance history of the vehicle

The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury, refer the repair or maintenance to a qualified mechanic.

VENTILATIONAlways store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating. Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane water heaters and furnaces.Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

1 - 6

1 - 7


1LABELS AND PICTOGRAMS

WARNING

Windshields do notprovide protectionfrom golf balls orother flying objects.

EGWHL14

WARNING

Keep entire bodyinside car.

27653G01

H O21 2 3

PP

PP PP74093-G01

74093G01

74821G05 For Rotomolded Bed

3598G02

MAX14o / 25%

MAX??? lbs.??? kg

MAX 5 in.12 cm

PP

MAX100 lbs.45 kg

74821G0

This Label Is Located On Governor Cover At Top Of Rear Axle.

DO NOT TAMPER WITH OR ATTEMPT TO CHANGE THE ADJUSTMENT OF THE GOVERNOR. GOVERNOR TAMPERING CAN RESULT IN SERIOUS PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY.

PP

MAX500 lbs.228 kg

MAX 5 in.12 cm

MAX14o / 25%

!35980G02

HORN

OFFON

71131-G01

71131G01

HORN

601781 !

!

""

" 14" 25%

"

"

!

" 14" 25% 35962-G01

28203G01

74099G01 608822

610631

608527

614068

614121

2820

3-G0

1

www.ezgo.com 6088

22

AUTHORIZED REPRESENTATIVE IN EC IS:

RANSOMES JACOBSEN LTD.WEST ROAD, IPSWICH,SUFFOLK, IP3 9TT, UK

614068

cm

MIN 150

RF

ON

OFF

I

O

ON

OFF

I

OF

RF

ON

OFF

I

O

ON

OFF

I

O

R

FON

OFF

I

O

ON

OFF

I

OR

F

< 14° 25% < 14° 25%

614121

MAX 4 in.10 cm MAX

14o / 25%

MAX250 lbs.110 kg

610631

71931G01

MAX 25 lbs. (11 kg)

74099-G01

74443G01

!

1. To Prevent Roll-Back On a Hill From a Stopped Position

3. Fully Release Park Brake

2. Apply Service Brake With Left Foot

4. Depress Accelerator While Releasing Service Brake As Vehicle Starts 74443G01

35493G01

" b35493-G01


1 - 8

1WARNING

READ MANUAL

!

WARNINGUSE CAUTION ININCLEMENT WEATHER

WARNINGDO NOT OPERATEUNDER THE INFLUENCEOF DRUGS OR ALCOHOL

MAX14û / 25%

MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED

!

< 14û 25%

WARNINGMAXIMUM CROSSHILL/RAMP ANGLE AS SPECIFIED

LOAD WITHHIGH CENTEROF GRAVITY COULD RESULTIN TIP OVER

LOADCENTEROF GRAVITY,MAXIMUMHEIGHT

!

< 14û 25%

WARNINGREAD MANUAL FOR MAXIMUM LOAD BEDCAPACITY.MAXIMUM RAMP/HILL

SECURE LOADAS FAR FORWARDAS POSSIBLE.MAXIMUM LOAD BEDCAPACITY

DO NOT RIDE INLOAD BED

DANGER OF EXPLOSIONDO NOT FILL GAS CAN IN LOAD BED

x inxx cm

MAX LOADXXX LBSXXX KG

WARNINGMAXIMUM LOAD & CENTER OF GRAVITY.KEEP LOAD AS FAR FORWARD AS POSSIBLE.DO NOT RIDE IN LOAD BED

KEEP HANDS & FINGERS AWAY FROM DUMP BED.DO NOT STAND BEHIND DUMPBED

1.

9.

10.

11.

12.

13.

14.

2.

3.

4.

5.

6.

7.

8.

PP

MAXXXX lbs.XXX kg

MAX XX in.XX cm

NOTE: All Pictograms may not apply to your product

1 - 9


11 3

H O2PPCLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE

PPUNLEADED GASOLINE

PPGROUND FUEL PUMP

PPDO NOT SPILL FUELON A HOTENGINE

NO TAMPERING.KEEP HANDS OUT

NEGATIVE GROUND BATTERY

DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND

SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION

DO NOT EXPOSE TO FLAME

WARNINGCORROSIVE

WARNINGLETHALVOLTAGE

WARNINGEXPLOSIVE

DO NOTDISPOSE OFBATTERIESIN LANDFILL

DO NOT DRIVE ON HIGHWAY

LOW OIL PRESSURE WINDSHIELDSDO NOTPROVIDE PROTECTION FROMFLYING OBJECTS

BATTERIES ARE HEAVY. USE CARE LIFTING

USE INSULATED TOOLS

WEAR EYE PROTECTION

NO SMOKING

HOT SURFACE

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.



1

P

F

OPERATE FROM DRIVERS SIDE ONLY

KEEP ARMS AND LEGS WITHIN VEHICLE

F

TO OPERATE VEHICLE IN FORWARD:TURN KEY TO ONMOVE DIRECTION SELECTOR TO FORWARDDEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY

R

TO OPERATE VEHICLE IN REVERSE:TURN KEY TO ONMOVE DIRECTION SELECTOR TO REVERSEAN AUDIBLE DEVICE WILL SOUNDDEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY

TO LEAVE A GASOLINE POWEREDVEHICLE IN PARK:APPLY PARKING BRAKETURN KEY TO OFFMOVE DIRECTION SELECTOR TOFORWARD

P

N

TO LEAVE AN ELECTRIC POWEREDVEHICLE IN PARK:APPLY PARKING BRAKETURN KEY TO OFFMOVE DIRECTION SELECTOR TONEUTRAL

ON

OFF

KEEP CLEARHAND OR FINGERS CANBE TRAPPED

ONPOSITION

OFFPOSITION

HEADLIGHTS

UNLOCKED

LOCKED

DIFFERENTIAL LOCKED

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.WARNINGKEEP ENTIRE BODYINSIDE CAR

MAXIMUM TAILGATELOAD

50.


1 - 10

1 - 11


1ENGINE CRANKINGPOSITION51. START

PULL HANDLE UPTO ENGAGE PARKBRAKE

52.

P

PULL HANDLE UP,PUSH BUTTON IN,PUSH HANDLE DOWNTO RELEASE PARK BRAKE

53.

1 2

3

AUXILIARY LIGHTS62.

HORN BUTTON

MINIMUM HEIGHT TO OPERATE VEHICLE IS59 INCHES (150 CM)

DO NOT OPERATE VEHICLE WHEN LIGHTNING IS INTHE AREA

63.

63.

63.

PUSH TOP OF SWITCH TO LOCK DIFFERENTIAL

PUSH BOTTOM OF SWITCH TO UNLOCK DIFFERENTIAL

58.

REAR DIFFERENTIALLOCK SWITCH59.

PUSH TOP PART OF SWITCH TO RAISE LOAD BED

PUSH BOTTOM PART OF SWITCH TO LOWER LOAD BED

61.

54.

WARNINGREAD OWNER'S MANUALBEFORE OPERATING VEHICLE IN FORWARD OR REVERSE

WARNINGREAD OWNER'S MANUALBEFORE ENGAGING TWOOR FOUR WHEEL DRIVE

57.

55.

WARNINGREAD OWNER'S MANUALBEFORE PARKING VEHICLE AND LEAVING IT UNATTENDED

56.

FORWARD

NEUTRAL

REVERSE

FRONT DIFFERENTIAL LOCK SWITCH.WARNINGREAD OWNER'S MANUAL BEFOREENGAGING FRONT DIFFERENTIALLOCK.DO NOT ENGAGE LOCK WHILE FRONT WHEELS ARE TURNED AND VEHICLE IS AT SPEED.

60.


cm

150


1
Notes:
1 - 12

2 - 1

GENERAL SPECIFICATIONSRead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

2

TITLE PAGE NO.

TERRAIN 500 Vehicle Specifications.............................................................................................................................. 2 - 3

TERRAIN 1000 Vehcile Specifications............................................................................................................................ 2 - 4

EXPRESS S4 Vehicle Specifications .............................................................................................................................. 2 - 5

EXPRESS L4 Vehicle Specifications .............................................................................................................................. 2 - 6

TERRAIN 500 & 1000 Vehicle Dimensions ..................................................................................................................... 2 - 7

EXPRESS S4 & L4 Vehicle Dimensions.......................................................................................................................... 2 - 8

TERRAIN 500 & 1000, EXPRESS S4 & L4 Vehicle Incline Information and Turning Diameter ................................... 2 - 9


2
Notes:
2 - 2

2 - 3


2MODEL: TERRAIN 500TYPE: GASOLINE POWERED TRUCKMODEL YEAR: 2012Part No: 618856

PRODUCT SPECIFICATION

Some items shown may be optional equipmentSpecifications are subject to change without notice

* Field installed accessories may require installation charges

Power SourceVehicle Power

Fuel Capacity 5.3 Gallons (20.0 L) tankDrive Train Continuously variable transmission (CVT)Transaxle Differential with helical gears

Forward - Reverse11.42:1 (Forward) 15.78:1 (Reverse)

4 Cycle 24.5 cu in (401.0 cc)

Valve TrainHorsepower (kW)

Electrical SystemBatteries (Qty, Type)

Air Cleaner

Cooling System

Gear SelectionRear Axle Ratio

Single Cylinder OHV13 hp (9.7 kW) Exceeds SAE J1940 Std.Starter/Generator. Solid State RegulatorOne, 12 Volt Maintenance Free

Replaceable Dry CartridgeKey or Pedal Start Pedal

Lubrication Pressurized Oil SystemOil Filter Spin-On

Air Cooled

Performance

Vehicle load capacity

2 Persons820.0 lb (375.0 kg) (Without Batteries)

Seating CapacityDry Weight

800.0 lb (360.0 kg)Bed load capacity 250.0 lb (110.0 kg)Curb Weight 860.0 lb (390.0 kg

Towing Capacity

20.3 ft (6.2 m)N/A

Outside Clearance CircleIntersecting Aisle Clrnce

250.0 lb (110.0 kg)

Speed (Level Ground) Fwd - 17.0 mph ± 0.5 mph (27.4 kph ± 0.8 kph)Rev - 12.3 mph ± 0.5 mph (19.8 kph ± 0.8 kph)

Steering & Suspension

Service Brake

Self-compensating rack and pinionLeaf springs with hydraulic shock absorbers

SteeringFront Suspension

Rear wheel mechanical self-adjusting drumRear Suspension Leaf springs with hydraulic shock absorbers

Self-compensating, single point engagementTrail Wolf 20 x 11 - 10 Uni-directional

Parking BrakeFront TiresRear Tires Trail Wolf 20 x 11 - 10 Uni-directionalBody & Chassis

Welded steel with DuraShield™ powder coatInjection molded TPO

FrameFront Body & Finish

Injection molded TPORear Body & FinishForest GreenStandard Color

Dimensions

Overall Height (No Canopy)Overall Height (With Canopy) Wheel BaseFront Wheel TrackRear Wheel TrackGnd Clearance @ DifferentialCargo Box Width (inside)

103.0 in (260.0 cm)49.0 in (124.0 cm)

Overall LengthOverall Width

65.5 in (166.0 cm)

38.5 in (97.0 cm)

44.5 in (113.0 cm)5.3 in (15.0 cm)

Cargo Box Length (inside) 30.5 in (77.0 cm)Cargo Box Depth (inside) 7.5 in (19.0 cm)Cargo Box Capacity 5.9 cu ft (0.17 m3)Cargo Box Material Roto-molded polyethylene

38.0 in (96.0 cm)

79.5 in (186.0 cm)49.0 in (124.0 cm) (Top of steering wheel)

PRODUCT OVERVIEW

Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by KawasakiOverhead valve

Drive Train: Automatic, continuously variable transmission (CVT)Electrical: Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve)

Transaxle: Differential with helical gears, ground speed governor, forward/reverseBrakes: Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release

with self-compensating systemCargo Bed: Roto-molded cross-linked polyethelene. Lifts for access to powertrain. Removable hinged multi-position

tailgate requires no latch mechanism

CONFIGURATION HIGHLIGHTS

Valve Train:Pressurized oil system, spin-on oil filterLubrication:Internal counter rotating balance shaftBalancer:

Fixed float bowl with remote pulse fuel pumpFuel System:Electronic spark/magnetoIgnition:Replaceable dry cartridgeAir Cleaner:

Noise & VibrationSound pressure; continued A-weighted equal to or lessthan 76 db(A)Highest RMS value of weighted acceleration is less than 2.5 m/s2

Highest RMS value of weighted acceleration is less than 2.5 m/s2

The uncertainty of measurement is 0.54 m/s2

Noise

Vibration, WBVVibration, HAV

Measurement methods were applied per the ISO 2631 and ISO 5349 standards under conditions of typical vehicle surfaces.


2 - 4

2 MODEL: TERRAIN 1000TYPE: GASOLINE POWERED TRUCKMODEL YEAR: 2012Part No: 618859


PRODUCT OVERVIEW

Some items shown may be optional equipment

Specifications are subject to change without notice* Field installed accessories may require installation charges




4 Cycle 24.5 cu in (401.0 cc)Valve TrainHorsepower (kW)Electrical SystemBatteries (Qty, Type)

Air Cleaner

Cooling System





Air Cooled

Performance





Towing Capacity

22.0 ft (6.7 m)N/A


250.0 lb (110.0 kg)Speed (Level Ground) 17.0 mph ± 0.5 mph (27.4 kph ± 0.8 kph)


Service Brake




Self-compensating, single point engagementStryker 22 x 9 - 10 Uni-Directional

Parking BrakeFront TiresRear Tires Stryker 22 x 9 - 10 Uni-DirectionalBody & Chassis



Steel. Base coat/clear coatRear Body & FinishForest GreenStandard Color

Dimensions

Overall Height (No Canopy)Overall Height (With Canopy) Wheel BaseFront Wheel TrackRear Wheel TrackGnd Clearance @ DifferentialCargo Box Width (inside)

111.5 in (283.0 cm)49.5 in (126.0 cm)


78.5 in (166.0 cm)

38.5 in (98.0 cm)

44.0 in (112.0 cm)5.3 in (15.0 cm)

Cargo Box Length (inside) 36.5 in (91.0 cm)Cargo Box Depth (inside) 10.5 in (27.0 cm)Cargo Box Capacity 9.2 cu ft (0.27 m3)Cargo Box Material Roto-molded poly/9.6 cu ft (0.27 m3)

38.0 in (96.0 cm)





with self-compensating systemCargo Bed: Roto-molded cross-linked polyethelene. Lifts for access to powertrain. Removable hinged multi-position

tailgate requires no latch mechanism




Noise & VibrationSound pressure; continued A-weighted equal to or lessthan 76 db(A)Highest RMS value of weighted acceleration is less than 2.5 m/s2

Highest RMS value of weighted acceleration is less than 2.5 m/s2


Noise



2 - 5


2MODEL: EXPRESS L4TYPE: GAS POWERED PERSONNEL CARRIERMODEL YEAR: 2012Part No: 618864


PRODUCT OVERVIEW

Some items shown may be optional equipmentSpecifications are subject to change without notice

* Field installed accessories may require installation charges





Air Cleaner

Cooling System





Air Cooled

Performance





Towing Capacity

20.3 ft (7.1 m)N/A


N/A



Service Brake




Self-compensating, single point engagementTerra Trac 22 x 11 - 10 / Polished Spoke Whls

Parking BrakeFront TiresRear Tires Terra Trac 22 x 11 - 10 / Polished Spoke WhlsBody & Chassis



Injection molded TPORear Body & FinishElectric BlueStandard Color

Dimensions

Overall Height (No Canopy)Overall Height (With Canopy) Wheel BaseFront Wheel TrackRear Wheel TrackGnd Clearance @ DifferentialLoad Bed Width

107.0 in (272.0 cm)46.5 in (118.0 cm)


65.5 in (166.0 cm)

38.5 in (98.0 cm)

40.0 in (102.0 cm)5.5 in (15.0 cm)

Load Bed Length 32.0 in (81.0 cm)

38.0 in (97.0 cm)





with self-compensating systemCapacity: Seating for 4 persons. Rear Seat converts to Cargo Bed




Noise & VibrationSound pressure; continued A-weighted equal to or lessthan 78 db(A)Highest RMS value of weighted acceleration is less than2.5 m/s2

Highest RMS value of weighted acceleration is less than2.5 m/s2


Noise




2 - 6

2 MODEL: EXPRESS S4TYPE: GAS POWERED PERSONNEL CARRIERMODEL YEAR: 2012Part No: 618862


PRODUCT OVERVIEW

Some items shown may be optional equipment

Specifications are subject to change without notice* Field installed accessories may require installation charges





Air Cleaner

Cooling System





Air Cooled

Performance





Towing Capacity

20.3 ft (7.1 m)N/A


N/A



Service Brake




Self-compensating, single point engagementTrail Wolf 20 x 11 - 10 Uni-directional

Parking BrakeFront TiresRear Tires Trail Wolf 20 x 11 - 10 Uni-directionalBody & Chassis



Injection molded TPORear Body & FinishForest GreenStandard Color

Dimensions

Overall Height (No Canopy)Overall Height (With Canopy) Wheel BaseFront Wheel TrackRear Wheel TrackGnd Clearance @ DifferentialLoad Bed Width

107.0 in (272.0 cm)46.5 in (118.0 cm)


65.5 in (166.0 cm)

38.5 in (97.0 cm)

40.0 in (102.0 cm)6.0 in (15.0 cm)

Load Bed Length 32.0 in (102.0 cm)

38.0 in (96.0 cm)





with self-compensating systemCapacity: Seating for 4 persons. Rear Seat converts to Cargo Bed




Noise & VibrationSound pressure; continued A-weighted equal to or lessthan 78 db(A)Highest RMS value of weighted acceleration is less than2.5 m/s2

Highest RMS value of weighted acceleration is less than2.5 m/s2


Noise



2 - 7


2

TERRAIN 500

103.0 in (260.0 cm)

65.5 in (166.0 cm)

Front38.0 in (96.0 cm)

Rear38.5 in (97.0 cm)

28.75 in (73.0 cm)

30.5 in (77.0 cm)

49.0 in(124.0 cm)

49.0 in(124.0 cm)

79.5 in(186.0 cm)

10.0 in(25.0 cm)

15.0 in(38.0 cm)

5.3 in(15.0 cm)

TERRAIN 1000

111.5 in (283.0 cm)

78.5 in (199.0 cm)

Front38.0 in (97.0 cm)

Rear38.5 in (98.0 cm)

30.25 in (76.8 cm)

36.0 in (91.0 cm)

49.5 in(126.0 cm)

49.5 in(126.0 cm)

73.0 in(185.0 cm)

11.5 in(29.0 cm)

18.0 in(46.0 cm)

5.3 in(15.0 cm)


2 - 8

2

Front

38.5 in (97 cm)Rear

38.0 in. (96 cm)

78.0 in.(198.0 cm)

49.0 in.(125.0 cm)

107.0 in (272.0 cm)65.5 in (166 cm)

6.0 in.(15.0 cm)

EXPRESS S4

46.5 in.(118.0 cm)

Front

38.5 in. (98 cm)Rear

38.0 in. (97 cm)

80.5 in.(203.0 cm)

49.0 in.(124.0 cm)

107.0 in (272.0 cm)65.5 in (166.0 cm)

5.5 in(15.0 cm)

EXPRESS L4

46.5 in.(118.0 cm)

2 - 9


2

TURNING CLEARANCE DIAMETER

TERRAIN 500 20.5 ft (6.3 m)TERRAIN 1000 23.5 ft (7.2 m)EXPRESS S4 20.5 ft (6.3 m)EXPRESS L4 20.5 ft (6.3 m)

RECOMMENDED MAX RAMP GRADE 25% or 14o MAX

RECOMMENDED MAX SIDE TILT25% or 14o MAX

2 - 10


Notes:2

INTRODUCTIONRead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

3

TITLE PAGE NO.

FEATURES.......................................................................................................................................................................... 3-3

General Information .................................................................................................................................................................................... 3-3

Key Switch / Headlight Switch..................................................................................................................................................................... 3-3

Low Oil Pressure Indicator Light................................................................................................................................................................. 3-4

Fuel Gauge ................................................................................................................................................................................................. 3-4

Direction Selector........................................................................................................................................................................................ 3-4

Accelerator Pedal........................................................................................................................................................................................ 3-4

Brake and Park Brake................................................................................................................................................................................ 3-4

Horn ............................................................................................................................................................................................................ 3-4

Rear View Mirror ......................................................................................................................................................................................... 3-5

Front Seats.................................................................................................................................................................................................. 3-5

Hip Restraint - Front.................................................................................................................................................................................... 3-5

Front Lights ................................................................................................................................................................................................ .3-5

Brake Light/Turn Signal............................................................................................................................................................................... 3-5

Volt Power Outlet ........................................................................................................................................................................................ 3-5

Glove Box.................................................................................................................................................................................................... 3-6

Cup Holder .................................................................................................................................................................................................. 3-6

Steering Wheel............................................................................................................................................................................................ 3-6

Choke.......................................................................................................................................................................................................... 3-6

Rear Seat .................................................................................................................................................................................................... 3-7

Hip Restraint - Rear .................................................................................................................................................................................... 3-7

Cargo Basket - If Equipped...................... .................................................................................................................................................. 3-7

Gun Holder - If Equipped ............................................................................................................................................................................ 3-7

Load Bed..................................................................................................................................................................................................... 3-7

Manual Lift Bed Operation .......................................................................................................................................................................... 3-8

Electric Lift Bed ........................................................................................................................................................................................... 3-8

3 - 1

3 -


N

3

otes:

2


3

FEATURES

General Information

If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’ position.

1. Key Switch / Headlight SwitchLocated on the dash panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key. To prevent inadvertent operation of the vehicle when left unattended, the key should be turned to the ‘OFF’ position and removed.

NOTICE

HORN PARK

5

7 6

ForwardReverse

4

ONOFF

FUEL

FE

2

1 3

13

12

3 - 3


3

2. Low Oil Pressure Indicator LightA low oil pressure indicator light is located on the dash panel. The light illuminates when the oil pressure is low. Check oil level. If oil level is between ADD and FULL mark on dipstick, a mechanical problem exists within the engine and the vehicle must not be driven. Contact a local distributor or authorized branch

3. Fuel Gauge The fuel gauge (if equipped) will either be located on the dash panel (electric) or directly on the fuel tank (mechani-cal).

4. Direction Selector

To reduce the possibility of component damage, the vehicle must be completely stopped before moving the direc-tion selector.

Located on the seat support panel, this lever permits the selection of either ‘F’ (forward) or ‘R’ (reverse). Vehicle should be left in ‘F’ when unattended.

5. Accelerator Pedal

Unintentional movement of the accelerator pedal will release the park brake and may cause the vehicle to move which could result in severe injury or death.With the key switch ‘ON’, depressing the accelerator pedal starts the engine. When the pedal is released, the engine will stop. To stop the vehicle more quickly, depress the service brake.

If key switch is ‘ON’ and park brake is set, depressing the accelerator inadvertently will release the park brake and will cause the vehicle to move which could cause severe injury or death.

Depressing the accelerator pedal will release the park brake if it is engaged. This is a feature to assure the vehicle is not driven with the park brake engaged. Depressing the accelerator pedal is not the preferred method of releasing the park brake.

Depressing the lower section of the brake pedal is the preferred method of releasing the park brake to assure the longest service life of brake components.

6. Brake and Park BrakeThe brake pedal incorporates a park brake feature. To engage, push down on the upper section of the pedal until it locks in place. The park brake will release when the service brake pedal is depressed. Use the lower section of the brake pedal to operate the service brake system.

7. HornThe horn is operated by pushing the horn button located on the floor to the left of the brake pedal.

NOTICE

3 - 4


3

8. Rear View MirrorThe rear view mirror is a two-position mirror manually adjusted for day and nighttime conditions.Sun Top kit is required to install rear view mirror.

9. Front SeatsThe split bench front seat is designed for one occupant on each side of the center console.

10. Hip Restraint - FrontThe front hip restraints are designed to help keep the occupants properly positioned in the event of sudden vehicle position changes.

11. Front Lights If the vehicle is equipped with lights, the key switch has a position to operate them, indicated by the light icon.

12. Brake Light/Turn SignalThe combination brake light/turn signal assemblies are located on the rear fenders.

13. 12 Volt Power OutletA 12 volt power outlet, rated at 15 amps, is located to the left side of the key/light switch. It provides constant power for accessories equipped with a 12 volt plug.

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3

14. Glove BoxA lockable glove compartment is located on each side of the instrument panel.

15. Cup HolderA cup holder is provided for convenience of both the driver and passenger.

16. Steering WheelThe steering wheel located in front of the driver seat is used to steer the vehicle. The steering wheel is also installed with scorecard holder assembly.

17. ChokeThe choke is used to aid cold starting. See COLD STARTING section for operating instructions.

17

9

16

12

15

14

21

22

23

Raise

Lower

24

10

3 - 6


3

18. Rear SeatThe rear seats is designed for two occupant on each side of the seat.

To prevent severe injury or death, rear seat passengers should hold on to both the hip restraints and the rear hand hold when the vehicle is in motion. Always be sure that all passengers are seated and holding on before operating vehicle.

19. Hip Restraint - Rear The rear hip restraints are designed to help keep the occupants properly positioned in the event of sudden vehicle position changes. Be sure that all passengers are seated and holding onto both the hip restraint and the rear hand hold (rear facing passengers) before operating the vehicle.

20. Cargo Basket - If EquippedDo not overload basket. The basket is limited to a maximum load of 25 lbs. (11 kg). Failure to follow these instructions could cause personal injury, damage to the vehicle and/or cause the vehicle to tip over. Be aware that increased loads may effect driving characteristics.

Never overload the basket. An overloaded basket could negatively affect vehicle handling characteristics and cause the vehicle to tip over or cause structural damage to the vehicle.

21. Gun Holder - If EquippedCheck that firearms are unloaded with the safety engaged before securing to holder. A maximum of two firearms can be secured in the gun holder.

To prevent severe injury or death, never transport loaded firearms on or in vehicle. Checkthat firearms are unloaded with the safety engaged and are properly secured with muzzlepointing in a safe direction before operating vehicle.

22. Load Bed

To reduce the possibility of severe injury or death, read, understand and follow the Warning label affixed to the front of the load bed. An electric lift bed is the standard bed for the ST 400. Lower capacity vehicles have a manual dump feature. A load bed warning label is affixed to the front of the bed. See Appendix A. For safe operation of the vehicle, this label must be understood. See the load bed warning label for maximum load. The load must be positioned in the bed as far for-ward as possible, distributed in such a way that its center of gravity must not be higher than height noted on label, and secured. Failure to follow these instructions may result in severe inju-ry, damage the vehicle and/or cause the vehicle to tip over. Use extra care when operating load-ed vehicle.Do not permit any one to ride in the load bed.

3 - 7


3

Do not drive the vehicle with the load bed raised or with the tailgate unsupported.When using a load bed, be sure to avoid backing up to the edge of a drop off, such as a loading dock or ravine. A misjudgment of distance or an unstable surface could result in the vehicle falling backwards.

23. Manual Lift Bed Operation

Exercise caution while operating the manual lift bed to ensure the bed is not released during lift-ing or lowering procedure. Severe injury could result if bed is released and traps fingers or other body parts.To raise the manual lift bed, pull back on the latch release handle immediately behind the driver seat. Raise the bed using the handle on the side of the bed.To lower the manual lift bed, grasp the bed handle and lower the bed to the rest position. Be sure hands are not trapped by the bed.

24. Electric Lift Bed

Exercise caution while operating the electric lift bed to ensure clothing is not caught during lifting or lowering procedure. Severe injury could result if bed is lowered and traps fingers or other body parts.The electric lift switch is located on the driver side of the front seat panel. Move the toggle switch lever up to raise the load bed and down to lower.Before operating load bed, check to ensure no one is behind the vehicle.

3 - 8

Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

INTRODUCTION

Notes:

3

3 - 9

3 - 10


Notes:

3

OPERATING PROCEDURESRead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

4

TITLE PAGE NO.

SERIAL NUMBER LOCATION............................................................................................................................................ 4-3

BEFORE INITIAL USE ........................................................................................................................................................ 4-4

OPERATING THE VEHICLE ............................................................................................................................................... 4-4

Run-in.......................................................................................................................................................................................................... 4-5

Cold Starting ............................................................................................................................................................................................... 4-6

STARTING AND DRIVING .................................................................................................................................................. 4-6

Starting The Vehicle.................................................................................................................................................................................... 4-6

Coasting...................................................................................................................................................................................................... 4-7

Fuel ............................................................................................................................................................................................................. 4-7

Battery......................................................................................................................................................................................................... 4-8

Sun Top And Windshield (If Equipped) ....................................................................................................................................................... 4-8

12 Volt Power Outlet ................................................................................................................................................................................... 4-9

Terrain......................................................................................................................................................................................................... 4-9

MODIFICATIONS TO VEHICLE .......................................................................................................................................... 4-9

LOAD BED .......................................................................................................................................................................... 4-9

MANUAL LIFT BED .......................................................................................................................................................... 4-10

TAIL GATE OPERATION .................................................................................................................................................. 4-10

4 - 1

4 - 2


Notes:

4


4

SERIAL NUMBER LOCATIONTwo serial number and manufacture date code plates are on the vehicle. One is placed on the body below the front, driver side of the seat. The other is located on the chassis between the seat back supports. To access it, raise the seat and lift up the flap on the access panel.Design changes take place on an ongoing basis. In order to obtain correct components for the vehicle, the manufac-ture date code, serial number and vehicle model mustacture date code, serial number and vehicle model must be provided when ordering service parts.

Serial Number & Location

Label No.

V

PAR

T A

PAR

T B

PAR

T C

/DPart A and B

Part C

Part D

Lift Flap on Access Panel

Serial Number Labels

4 - 3


4

BEFORE INITIAL USERead and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle and its equipment as well as how to use it safely. Maintaining good performance depends to a large extent on the operator.

Before a new vehicle is put into operation, the items shown in the INITIAL SERVICE CHART must be performed.Vehicle battery must be fully charged before initial use.Check for correct tire inflation. See GENERAL SPECIFICATIONS.Check for oil or fuel leaks that could have developed in shipment from the factory.Determine and record braking distance required to stop vehicle for future brake performance tests.Remove the protective clear plastic, that protect the seat bottom and back rest during shipping, before placing the vehicle in service.

Initial Service Chart

OPERATING THE VEHICLE

Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance.Read and understand the following warnings before attempting to operate the vehicle.

To reduce the possibility of severe injury or death resulting from loss of vehicle control, the fol-lowing warnings must be observed:When driving vehicle, consider the terrain, traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle.Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.Stay in designated areas and avoid extremely rough terrain.Maintain a safe speed when driving down hill. Use service brake to control speed when traveling down an incline. A sudden stop or change of direction may result in loss of control.Slow down before and during turns. All turns should be made at reduced speed.Never drive vehicle up, down, or across an incline that exceeds 14° (25% grade).

ITEM SERVICE OPERATION

Battery Charge batterySeats Remove protective plastic coveringBrakes Check operation and adjust if necessary Check hydraulic brake fluid level if equipped Establish acceptable stopping distanceTires Check air pressure (see SPECIFICATIONS)Fuel Fill tank with correct fuelEngine Check oil level

4 - 4


4

To reduce the possibility of severe injury or death resulting from improper vehicle operation, the following warnings must be observed:Refer to GENERAL SPECIFICATIONS for seating capacity.Depressing accelerator pedal will release foot operated park brake and may cause inadvertent vehicle movement. Turn the key to the ‘OFF’ position whenever the vehicle is parked.To prevent inadvertent movement when the vehicle is to be left unattended, engage the park brake, move direction selector to forward position, turn key to ‘OFF’ position and remove key.Make sure that the direction selector is in correct position before attempting to start the vehicle.Always bring the vehicle to a complete stop before shifting the direction selector.

Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance.

Do not take vehicle out of ‘gear’ while in motion (coast).

Check the area behind the vehicle before operating in reverse.

All occupants must be seated. Keep entire body inside vehicle and hold on while vehicle is in motion.

RUN-INCheck for oil or fuel leaks that could have developed in shipment from the factory. Avoid full throttle starts and rapid acceleration until the engine has achieved operating temperature.All engines consume more oil than normal during the first hours of operation. As internal moving parts are run-in, oil consumption should gradually decrease until the rate of consumption stabilizes.Check the oil level per the Periodic Service Schedule. Add oil if the level on the dipstick indicates that oil is in the add oil range.

Check Oil Level on Dipstick

Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.

The oil dipstick/fill cap must be in place before operating the engine. Failure to install the dipstick/fill cap will result in oil becoming contaminated and/or being discharged into the engine compartment.

Maximum Oil LevelFor Hot EngineDo Not Overfill

Fill Cold EngineTo This Point

SafeOperating Range

Hot Engine

Add Oil

NOTICE

4 - 5


4

Oil dipsticks are unique to this model vehicle. Do not interchange oil dipsticks between models.The oil should be changed in accordance with the Periodic Service Schedule while the engine is warm. See SERVICE AND MAINTENANCE for checking oil level and changing oil procedures.

Clean Entire Dipstick

COLD STARTINGStarting a cold engine may require use of the choke. Depress the accelerator approximately 1" (2.5 cm) or until the starter just begins to operate. Pull the choke out if required. Accelerate slowly and push the choke in completely when the engine runs smoothly.

Do not allow the starter to operate continuously for more than 10 seconds. Allow 30 seconds between startingattempts. If the vehicle does not start on the third attempt, turn the key switch off, set the park brake and deter-mine the cause of the problem.If the vehicle had been running and the engine does not start within 10 seconds, use the choke.

STARTING AND DRIVING

To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release service brake until engine has started.To operate vehicle:

• Apply the service brake, place the key in the key switch and turn it to the ‘ON’ position. • Move the direction selector to the direction desired.• Release the park brake by depressing the service brake pedal until the park brake releases. • Slowly depress the accelerator pedal to start the engine. Release service brake when engine starts.• When the accelerator pedal is released, the ignition circuit is de-energized and the engine stops. To stop the

vehicle more quickly, depress the service brake pedal

When the direction selector is in the reverse position, a warning signal will sound to indicate that the vehicle is ready turn in reverse.

STARTING THE VEHICLE ON A HILL

To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release service brake until engine has started.

NOTICE

4 - 6


4

Do not hold vehicle on hill by using accelerator and engine. This will cause premature and excessive wear to drivetrain components.To reduce the possibility of permanent damage to the drive system, it is important to prevent excessive roll-back when starting the vehicle on a hill.Place left foot on service brake and release the park brake. Depress accelerator with right foot and release the ser-vice brake by lifting left foot.

COASTING

To reduce the possibility of severe injury or death from coasting at above recommended speeds, limit speed with service brake.On steep hills, it is possible for the vehicle to coast at greater than normal speeds encountered on a flat surface. To reduce the possible loss of vehicle control and severe drivetrain damage, speeds should be limited to no more than the maximum governed speed on level ground (see GENERAL SPECIFICATIONS). Limit speed by applying service brake.

FUEL

To reduce the possibility of severe injury or death from improper fuel handling:Do not smoke near the fuel tank.Do not refuel near open flame or electrical items which could produce a spark.Always handle gasoline in a well ventilated area.Always wear eye protection to protect against splashed fuel and fuel vapors.Always allow adequate space for the expansion of gasoline. Leave at least 1" (2.5 cm) space below bottom of filler neck.Inspect fuel cap, tank and other components for leaks or deterioration that could cause a hazard-ous condition.

The fuel tank is located under the seat on the passenger side of the vehicle. Fill the tank with fresh, clean, automo-tive grade gasoline. High altitude or heavy use/load applications may benefit from higher octane gasoline.Do not use gasoline which contains Methanol.

Some fuels, called oxygenated or reformulated gasoline, are gasoline blended with alcohols or ethers. Excessive amounts of these blends can damage the fuel system or cause performance problems. If any undesirable operating symptoms occur, use gas-oline with a lower percentage of alcohol or ether.Use fresh regular grade unleaded fuel. Ethanol blend fuel up to 10% is permissible.

4 - 7


4
Fueling
BATTERY

Excessive use of accessories may drain the battery and leave insufficient reserve to start the vehicle.The vehicle uses a combination starter/generator to both start the engine and charge the battery. The engine will not idle; therefore, the battery cannot be charged while the vehicle is stopped. Do not operate accessory items (such as lights) excessively while the vehicle is stopped.The generator is capable of supplying 35 amps; therefore, operation of all accessories could result in the discharge of the battery even though the engine is running and the generator operating. Discharging the battery is known as deep cycling. The battery is not a deep cycle model, but is a starting battery. Multiple deep cycling will result in the premature failure of the battery.If the vehicle battery has become discharged, it must be charged using a 12 volt charger that is rated at 10 amps or less and in accordance with all instructions provided by the manufacturer of the charger.

SUN TOP AND WINDSHIELD (If Equipped)

The sun top does not provide protection from roll over or falling objects.The windshield does not provide protection from tree limbs or flying objects.

To prevent damage to the vehicle, do not hold on to sun top struts and stand on body panels.

The sun top and windshield provide some protection from the elements; however, they will not keep the operator and passenger dry in a downpour. This vehicle is not equipped with seat belts and the sun top has not been designed to provide roll over protection. In addition, the sun top does not protect against falling objects nor does the windshield protect against flying objects and tree limbs. Keep arms and legs inside of vehicle while it is moving.

1" Min.(2.5 cm)

Fuel

4 - 8


4

12 VOLT POWER OUTLET

Overuse of accessories may drain the battery and leave insufficient reserve to start the vehicle.A 12 volt power outlet, rated at 15 amps, is located left side of the key/light switch

12 Volt Power Outlet

TERRAINnot on public highways). The vehicle may also be used on established trails or open terrain that is free fromstumps, large rocks or holes. The vehicle should not be used to cross water.

MODIFICATIONS TO VEHICLE

Changes to the weight distribution or the center of gravity may make vehicle unstable or prone to roll over which could result in severe injury or death to the operator or passengers.

Do not modify the vehicle in any manner that will change the weight distribution of the vehicle. Changes to the weight distribution or the center of gravity may make it unstable or prone to roll over which could result in severe injury or death to the operator or passengers.

LOAD BED

To reduce the possibility of severe injury or death, read, understand and follow the Warning label affixed to the front of the load bed. An electric lift bed is the standard bed for the ST 400. Lower capacity vehicles have a manual dump feature. A load bed warning label is affixed to the front of the bed. See Appendix A. For safe operation of the vehicle, this label must be understood. See the load bed warning label for maximum load. The load must be positioned in the bed as far forward as possible, distributed in such a way that its center of gravity must not be higher than height noted on label, and secured. Failure to follow these instructions may result in severe injury, damage the vehicle and/or cause the vehicle to tip over. Use extra care when operating loaded vehicle.

12V PowerOutlet

ONOFF

FUEL

FE

4 - 9


4

Do not permit any one to ride in the load bed.Do not drive the vehicle with the load bed raised or with the tailgate unsupported.When using a load bed, be sure to avoid backing up to the edge of a drop off, such as a loading dock or ravine. A misjudgment of distance or an unstable surface could result in the vehicle falling backwards.

MANUAL LIFT BED

Exercise caution while operating the manual lift bed to ensure the bed is not released during lifting or lowering procedure. Severe injury could result if bed is released and traps fingers or other body parts.

To lift the manual lift bed, pull back on the latch release handle immediately behind the driver seat. Raise the bed using the handle on the side of the bed.

Manual Bed LatchOn the ST 400, the gas strut will assist in raising the empty load bed and will keep the bed raised.Over time, the gas strut may allow the load bed to slowly lower. If this condition is evident, replacement of gas strut is

required. To lower the manual lift bed, grasp the bed handle and lower the bed to the rest position. Be sure hands are not trapped by the bed.

TAIL GATE OPERATIONTo open the tail gate, lift tail gate straight up with a sharp upward pull to lift out of the closed position and pivot out for open position. To remove the tail gate, remove the side cables from the load bed and open tail gate until it is straight down, move tail gate panel straight up to remove from pins and remove from the load bed. Reassemble in reverse order.

Front of Vehicle

Manual Load Bed LatchPull Up to Release

NOTICE

4 - 10


4

Gas Strut with Tether Cable

Never fill a gas can in the bed of a vehicle. Static discharge could ignite gasoline vapor and cause an explosion.

Always place a gas can on the ground before filling. Never fill a gas can in the bed of the vehicle. Static electricity is built up during the fueling process and could discharge causing the gasoline vapor to ignite.

4 - 11


4

Notes:

4 - 12

MAINTENANCERead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

5

TITLE PAGE NO.

VEHICLE CLEANING AND CARE ...................................................................................................................................... 5-5

Vehicle Cleaning ......................................................................................................................................................................................... 5-5

COMMON SENSE OPERATION ......................................................................................................................................... 5-6

ENVIRONMENTAL CONCERNS......................................................................................................................................... 5-6

REPAIR ............................................................................................................................................................................... 5-7

Lifting the Vehicle........................................................................................................................................................................................ 5-7

WHEELS AND TIRES.......................................................................................................................................................... 5-8

Tire Repair .................................................................................................................................................................................................. 5-8

Wheel Installation........................................................................................................................................................................................ 5-9

LIGHT BULB REPLACEMENT ......................................................................................................................................... 5-10

FUSE REPLACEMENT ..................................................................................................................................................... 5-10

VEHICLE DISCHARGED BATTERY ................................................................................................................................. 5-10

TRANSPORTING VEHICLE .............................................................................................................................................. 5-11

Towing....................................................................................................................................................................................................... 5-11

Neutral Lock.............................................................................................................................................................................................. 5-11

Hauling ...................................................................................................................................................................................................... 5-11

SERVICE AND MAINTENANCE ....................................................................................................................................... 5-12

ROUTINE MAINTENANCE................................................................................................................................................ 5-13

Tire Inspection........................................................................................................................................................................................... 5-13

Rear Axle .................................................................................................................................................................................................. 5-13

Four Cycle Engine..................................................................................................................................................................................... 5-13

Checking the Oil Level .............................................................................................................................................................................. 5-13

Changing Oil ............................................................................................................................................................................................. 5-14

STARTER/GENERATOR BELT TENSION........................................................................................................................ 5-17

Adjusting The Belt ..................................................................................................................................................................................... 5-18

BATTERY CLEANING....................................................................................................................................................... 5-18

BRAKES............................................................................................................................................................................ 5-19

PERIODIC BRAKE TEST FOR MECHANICAL BRAKES ................................................................................................. 5-19

AIR INTAKE AND COOLING FINS ................................................................................................................................... 5-20

REAR AXLE ...................................................................................................................................................................... 5-20

Checking the Lubricant Level.................................................................................................................................................................... 5-20

AIR CLEANER INSPECTION AND REPLACEMENT ....................................................................................................... 5-21

Cleaning the Air Filter Element ................................................................................................................................................................. 5-21

5 - 1


5 - 2

5

TITLE PAGE NO.

LUBRICATION ..................................................................................................................................................................5-22

SPARK PLUGS .................................................................................................................................................................5-22

PROLONGED STORAGE..................................................................................................................................................5-23

PERIODIC SERVICE SCHEDULE.....................................................................................................................................5-25

CAPACITIES AND REPLACEMENT PARTS ....................................................................................................................5-27

HARDWARE......................................................................................................................................................................5-27

5 - 3

Notes:Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

MAINTENANCE

5


5

Notes:

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VEHICLE CLEANING AND CAREVehicle Cleaning

To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.

When pressure washing exterior of vehicle, do not use pressure in excess of 700 psi. To reduce the possibility of cosmetic damage, do not use any abrasive or reactive solvents to clean plastic parts.

It is important that proper techniques and cleaning materials be used. Using excessive water pressure may cause severe injury to operator or bystander, damage to seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi to wash exterior of vehicle.Clean windshield with lots of water and a clean cloth. Minor scratches may be removed using a commercial plastic polish or Plexus® plastic cleaner available from the service parts department.Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth.Removal of oil, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinyl/rubber cleaner.The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surfaces.Occasional cleaning and waxing with non-abrasive products designed for ‘clear coat’ automotive finishes will enhance the appearance and durability of the painted surfaces.Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle. These materi-als will cause corrosion of underbody parts unless flushed occasionally with plain water. Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be loosened to ease it’s removal, taking care not to chip or otherwise damage paint.

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COMMON SENSE OPERATION

To prevent severe injury or death, observe the following:Never transport loaded firearms on or in vehicleCheck that firearms are unloaded with the safety engaged and are properly secured with muzzle pointing in a safe direction before operating vehicle. Be aware of other firearms in proximity to operator and passengers.This vehicle is not a toy. If not operated properly and responsibly, it can cause severe injury or death to the opera-tor, passengers or bystanders. All operators should possess a valid driver’s license. Children should not be permitted to operate the vehicle. Children may not have the skill, judgement or strength to operate this or similar vehicles.Alcohol, drugs and many over the counter medications reduce the ability of the driver to operate the vehicle safely. Always review side effects of any medication with a doctor or pharmacist before operating vehicle.Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when oper-ating vehicle in rough or densely wooded terrain.When driving at full speed on a dirt road, loose surfaces or wet grass, vehicle stopping distance will increase. If the vehicle is fully loaded, it will take longer to stop than with no load. When operating vehicle in wet weather conditions, remember that the brakes may need to be lightly applied in order to provide enough friction to dry the brake unit. If wet, the brakes will lose much of their effect.Slow down when in unfamiliar terrain. Slow down when cresting a hill in an area that you are unfamiliar with.Some hills are too steep to climb. If you attempt to climb a hill that is too steep or if you are unable to achieve ade-quate traction, do not attempt to turn around on the hill. Slowly back straight down the hill using the service brake to control speed.

ENVIRONMENTAL CONCERNS

As a responsible user, practice respect for all wildlife and their habitat. Respect private property and comply with all local laws and regulations governing the use of light duty utility vehicles. To prevent severe injury or death while driving, be aware of the following:Environmental hazards such as steep slopes, overhanging limbs, etc.Danger of fire when vehicle is operated over dry combustible organic material.When driving, be aware of environmental hazards such as steep slopes, overhanging limbs, etc. Be aware of the danger of fire when the gasoline powered vehicle is operated over dry combustible organic material.

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REPAIRSome servicing operations may require the front wheels, the rear wheels, or the entire vehicle to be raised.

To reduce the possibility of severe injury or death from a vehicle falling from a jack:Be sure the vehicle is on a firm and level surface.Never get under a vehicle while it is supported by a jack.Use jack stands and test the stability of the vehicle on the stands.Always place chocks in front and behind the wheels not being raised.Use extreme care since the vehicle is extremely unstable during the lifting process.

When lifting the vehicle, position the jacks and jack stands at the areas indicated only.

Lifting The VehicleTool List Qty. Tool List Qty.Floor jack .................................................................... 1 Jack stands .............................................................4Wheel Chocks............................................................. 4

Remove payload from vehicle before lifting. No person(s) should be in or on the vehicle while lifting.To raise the entire vehicle, install chocks in front and behind each front wheel. Center the jack under the rear frame crossmember. Raise the vehicle enough to place a jack stand under the outer ends of the rear axle.Lower the jack and test the stability of the vehicle on the two jack stands.Place the jack at the center of the front axle. Raise the vehicle enough to place jack stands under the frame crossmember as indicated.Lower the jack and test the stability of the vehicle on all four jack stands.If only the front or rear of the vehicle is to be raised, place the chocks in front and behind each wheel not being raised to stabilize the vehicle.Lower the vehicle by reversing the lifting sequence.

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WHEELS AND TIRES

A tire explosion can cause severe injury or death. Never exceed the inflation pressure rating on the tire sidewall.To reduce the possibility of tire explosion, pressurize tire with small amounts of air applied inter-mittently to seat beads. Due to the low volume of the small tires, overinflation can occur in sec-onds. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face and eyes from escaping air when removing a valve core.To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets designed for impact wrench use.DO NOT use low inflation tires on any E-Z-GO vehicle. DO NOT use any tire which has a recom-mended inflation pressure less than the inflation pressure recommended in the owner’s guide.Use caution when inflating tires. Overinflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause severe injury.

Tire RepairTool List Qty. Tool List Qty.Lug wrench, 3/4" ..........................................................1 Impact socket, 3/4" 1/2" drive ................................. 1Impact wrench, 1/2" drive ............................................1 Torque wrench, 1/2" drive. ...................................... 1

Use caution when inflating tires. Due to the low volume of the small tires, overinflation can occur in seconds. Overin-flation could cause the tire to separate from the wheel or cause the tire to explode.Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section for rec-ommended tire inflation pressure. For outdoor applications with major use on grassy areas, the following should be considered. On hard turf, it is desirable to have a slightly higher inflation pressure. On very soft turf, a lower pres-sure reduces the possibility of tires cutting into the turf. For vehicles being used on paved or hard surfaces, tire infla-tion pressure should be in the higher allowable range, but under no condition should inflation pressure be higher than recommended on tire sidewall. All four tires should have the same pressure for optimum handling characteristics. Be sure to install the valve stem dust cap after checking or inflating.The vehicle is fitted with low pressure tubeless tires mounted on one piece rims; therefore, the most cost effective way to repair a puncture in the tread is to use a commercial tire plug.

View from Underside of Vehicle

Lifting The Vehicle

Center ofFront Axle

Flat Portionof Frame

Outside Endof Rear Axle

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Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel.

If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire. Immerse the tire in water to locate the leak and mark with chalk. Insert tire plug in accordance with manufacturer’s instruc-tions.

To reduce the possibility of severe injury, be sure the mounting/demounting machine is anchored to floor. Wear OSHA approved safety equipment when mounting/demounting tires.If the tire is to be removed or mounted, the tire changing machine manufacturer’s recommendations must be fol-lowed in order to reduce possibility of severe injury.

Wheel Installation

To reduce the possibility of component damage, do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.

It is important to follow the ‘cross sequence’ pattern when installing lug nuts. Thiswill assure even seating of the wheel against the hub.

With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Finger tighten the lug nuts (1) in a ‘cross sequence’ pattern. Tighten the lug nuts to 50 to 85 ft. lbs. (68 to 115 Nm) torque in 20 ft. lbs. (27 Nm) increments following the ‘cross sequence’ pattern.

Unidirectional TiresSome vehicles may be fitted with unidirectional tires. These tires may be identified by a directional arrow on the sidewall. Be sure to position the wheel on hub correctly with arrow indicating direction of rotation when moving forward.

NOTICE

Valve Stem Cap

Cross Sequence

Tire style may vary

NOTICE

Tire style may vary

1

2

3

4

'Cross Sequence'

Front ofVehicle

Rotation

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LIGHT BULB REPLACEMENT

To reduce the possibility of premature bulb failure, do not touch new bulbs with bare fingers. Use clean, dry tissue or paper towel to handle the glass portion of the bulb. For vehicles equipped with lights mounted in the cowl, locate bulb socket on backside of light and turn bulb socket a quarter turn counterclockwise to unlock and pull out bulb and socket. Insert new bulb and rotate socket a quarter turn clockwise to secure.

Similarly replace the turn signal light bulb, locate bulb socket on backside of light bar and turn bulb socket a quarter turn counterclockwise to unlock and pull out bulb and socket. Insert new bulb and rotate socket a quarter turn clockwise to secure.Two tail light types were used depending upon the vehi-cle model; select the type that is installed in the vehicle and follow the instructions for replacing the tail light bulb.

To replace the tail and brake light bulb, roll the rubber bezel from around the edge of the taillight and remove lens. Install replacement bulb and replace lens. To replace the tail and brake light bulb, remove hardware securing lens and remove lens. Install replacement bulb.

FUSE REPLACEMENTTo replace fuses, locate the fuse block under the driver side seat. Pull out old fuse and replace with a new automo-tive type fuse. Headlight and taillight bulbs and fuses are available from a local Distributor, an authorized Branch or the Service Parts Department.

VEHICLE WITH A DISCHARGED BATTERY

To reduce the possibility of severe injury or death from inadvertent motion, do not attempt to ‘jump start’ a vehicle.The vehicle is equipped with a starter/generator and does not idle. When starting the engine, the starter/generator functions as a starter and with the engine running, it functions as a generator.With the short running times associated with this kind of vehicle, the generator is more than adequate to maintain the battery charge level. The generator is not designed to charge a discharged battery.

Inside of Cowl

Headlight Casing

Screw

HeadlightBulb

RearFender

Tail LightLens

Tail LightBulb

RearFender

Tail/BrakeLight

Roll RubberBezel AwayFrom Body

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When engine starts, the clutches engage and cause vehicle to move making ‘jump starting’ both dangerous and impractical.If the vehicle battery has become discharged, it must be charged using a 12 volt charger that is rated at 10 amps or less. Read and understand all instructions provided by the manufacturer of the charger.

TRANSPORTING VEHICLETOWING

This vehicle is not designed to be towedIt is recommended that the vehicle be moved by placing the entire vehicle on a trailer, flatbed truck or other suitable transport.

NEUTRAL LOCKTo prevent the driven clutch from turning the rear wheels during service operations, a neutral lock is located on the direction selectorTo operate:Turn key switch to ‘OFF’ and lift seat. Pull out and rotate the neutral lock pin handle so that the pointed portion of the handle is to the side of the direction selector cam. Move direction selector towards the area between ‘F’ and ‘R’. Dur-ing that motion the pin will snap into the hole in the direction selector mounting bracket preventing any movement.

When in this position, the direction selector remains locked in the neutral position. To unlock the direction selector, pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole in the direction selector cam.

HAULING

To reduce the possibility of severe injury or death while transporting the vehicle:Secure the vehicle and contents.Never ride on the vehicle being transported.Always remove the windshield before transporting.

2

1

3Hole in DirectionSelector Cam

Unlocked

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If the vehicle is to be transported at highway speeds, the sun top must be removed and the seat bottom secured. When transporting vehicle below highway speeds, check for tightness of hardware and cracks in sun top at mounting points. Always remove windshield when transporting. Always check that the vehicle and contents are adequately secured before transporting. The rated capacity of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load plus 1000 lbs. (454 kg). Secure the vehicle using ratchet tie downs.

SERVICE AND MAINTENANCE

To reduce the possibility of severe injury or death from improper servicing techniques:DO NOT attempt any type of servicing operations before reading all notes, cautions and warn-ings in this manual.Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with both drive wheels raised and vehicle properly supported on jack stands.To reduce the possibility of motor damage, never operate vehicle at full throttle for more than 4 - 5 seconds while vehicle is in a ‘no load’ condition.Reduce the possibility of accidental starting by disconnecting battery at negative terminal before servicing.

Wear eye protection when working on the vehicle. Use extra care when work-ing around batteries, or using solvents or compressed air.To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the battery before removing battery wires.

Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench ‘shorting out’ a battery, which could result in an explosion.The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Contact a physician immediately.

Any electrolyte spills should be neutralized with a solution of 2 teaspoons (10 ml) sodium bicar-bonate (baking soda) dissolved in 1 quart (1 liters) of water and flushed with water.Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to reduce the possibility of can contacting battery terminals which could result in an explosion. It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual. Preventative maintenance, applied at recommended intervals, is the best guarantee for keeping the vehicle both dependable and economical.This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic Service Schedule for appropriate service intervals.

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ROUTINE MAINTENANCE

To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures, extreme dust/debris conditions, or frequent use with maximum load.To access the powertrain for routine maintenance, lift or remove the seat and remove the rear access panel. For major repair, refer to the appropriate Technician’s Repair and Service Manual.Some service procedures may require the vehicle to be lifted. Refer to LIFTING THE VEHICLE for proper lifting pro-cedure and safety information.

Tire InspectionTire condition should be inspected per the Periodic Service Schedule. Inflation pressures should be checked when the tires are cool. Be sure to install the valve dust cap after checking or inflating.

Rear AxleThe only maintenance required for the first five years is the periodic inspection of the rear axle for lubricant leakage. Unless leakage is evident, the lubricant need only be replaced after five years. Refer to the Service and Repair Man-ual for the fluid replacement procedure.

FOUR CYCLE ENGINE

Engine SpecificationsEngine model .............................................................................................................................................. FJ400DType ............................................................................................................................................... Four cycle, OHVNumber of cylinders ................................................................................................................................................1Displacement ................................................................................................................................................. 401 ccRated horsepower............................................................................................................................................13 hpSpark plug type ..................................................................................................................................NGK BPR2ESSpark plug gap .............................................................................................................. .028" - .031" (.70 - .80 mm)Cooling..........................................................................................................................................Forced air cooledOil Filter......................................................................................................................... Cartridge type full flow filterOil Pump ......................................................................................................................Positive displacement pump

Engine DescriptionThe engine is an air cooled, 4-stroke, OHV, single cylinder gasoline engine. It incorporates a pressure fed lubrication positive displacement oil pump with a cartridge type full flow oil filter and a counter rotating balance shaft.

CHECKING THE OIL LEVEL

Do not overfill engine. Too much oil may cause engine to smoke or cause spark plug fouling.Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.The oil should be checked with the engine warm. The vehicle should be on a level surface with the parking (PARK) brake engaged. Allow adequate time for oil to drain into the crankcase before checking.

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Remove the dipstick and wipe off the entire area with a lint free cloth.

Insert the dipstick fully into the dipstick hole and remove. Examine the level of the oil on the dipstick.

The engine can be operated safely as long as oil is within the safe operating range as indicated on the dip stick. Do not operate vehicle if oil level is below the safe area indicated on the dipstick.Oil should be added to bring the level into the safe operating range. Remember that oil expands as it gets hot, Do not overfill. Check that the oil cap is firmly in place.

When adding oil between oil changes, do not mix brands and viscosity grades of oil

The oil dipstick/fill cap must be in place before operating the engine. Failure to install the dipstick/fill cap will result in oil becoming contaminated and/or oil being discharged into the engine compartment.

Changing the OilTool List Qty.Socket, 3/8" drive.................................................................................................................................................... 1Ratchet, 3/8" drive .................................................................................................................................................. 1Extension, 3/8" drive, 8".......................................................................................................................................... 1Oil drain pan ........................................................................................................................................................... 1Wrench, 3/4" ........................................................................................................................................................... 1

For maximum performance and longevity, the engine oil should be replaced after the first 8 hours of operation. After the initial oil change, it should be changed every 125 hours of operation or semi-annually, whichever comes first.

Maximum Oil LevelFor Hot EngineDo Not Overfill

Fill Cold EngineTo This Point

SafeOperating Range

Hot Engine

Add Oil

NOTICE

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The selection of oil is dependent upon the service that the vehicle will perform. Most vehicles require 10W-30 oil, whereas vehicles used at capacity or near capacity load applications will utilize 10W-40 oil after a break-in period of 100 hours.

If vehicle is to be stored over winter months, it can be stored with old oil left in engine. The oil should be changed as part of spring maintenance. This will remove any moisture that has accumulated during storage.

Be aware that engine fluids may be hot and contact to the skin may cause severe burns. Wear rubber gloves to protect skin from exposure to the old oil and degreaser.

The oil should be changed with engine warm. Park vehicle on a level surface, engage parking brake and remove key. Place a drain pan under engine. Wipe top of the engine clean with a cloth. Remove the oil fill cap.

Clean the area around filter. Using a filter wrench, strap wrench or other suitable wrench, remove the filter (B) from the engine and allow the oil to drain. The ‘O’ rings may remain on engine (A) or filter (B)

-20 0 20 40 60 80 100

-30 -20 -10 0 10 20 30 40C

F 0

0

10W-3010W-30

10W-4010W-40

HEAVY DUTY WORK

LIGHT DUTY WORK

(AIR TEMPERATURE)

10W-3010W-30

NOTICE

Oil Fill Cap

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Inspect the filter. Make sure the ‘O’ ring is not left on the engine surface.

Be careful of hot oil when drained. It may be hot enough to burn you severelyDrain the oil by removing the drain plug found at the rear of the engine base. Remove using a 3/4" wrench. At the first oil change, small metal chips and lint may be found. This is normal, resulting from the break-in period. Inspect the filter at every oil change. The presence of large metal chips could indicate possible damage to the engine.

Wipe the area around the drain plug mount with a lint free cloth and inspect the drain plug (A) for damage; replace if necessary. Replace the "O"-ring (B) with a new one and tighten to 61 in. lbs. (7.0 Nm) torque. Apply engine oil to the oil filter seal and install oil filter onto the engine until the seal contacts mounting surface of the engine. Then turn the filter 2/3 to 3/4 rotations by HAND(S). Pour in the specified type and amount of oil See “Capacity and Replacement Parts” chart on page 55.Oil capacity is 1 1/3 quarts (1.3 liters). Add slightly less than 1 1/3 quarts (1.3 liters) to allow for possible residual oil left in engine. The oil must be high quality oil that meets or exceeds API SF, SG, CC standards. Check oil level on dipstick. Oil should be slightly below ‘H’ to allow for expansion. If necessary, continue to add oil slowly and allow time for oil to flow down into engine. Check oil level on dipstick. Do not overfill.

Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.

Both the oil dipstick and fill cap must be in place before operat-ing the engine. Failure to install the dipstick and fill cap will result in oil being discharged into the engine compartment

NOTICE

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As a final check, check the oil level again with the vehicle on level ground. Like all liquids, oil increases in volume when warm. The full ‘H’ mark on the dipstick is calibrated for an engine at operating temperature. When the engine is cold, the oil will be below the full mark. The engine can be operated safely as long as the oil is within the safe oper-ating range as indicated on the dipstick. Do not operate vehicle if oil level is below the safe area indicated on the dipstick.

STARTER/GENERATOR BELT TENSIONTool List Qty.Belt tension gauge ..................................................................................................................................................1Wrench, 3/4" ...........................................................................................................................................................1Wrench, 9/16" .........................................................................................................................................................2Ratchet, 3/8" drive...................................................................................................................................................1Socket, 3/4", 3/8" drive............................................................................................................................................1

The starter/generator belt tension should be checked after the first 15 - 20 hours and set to 75 - 80 lbs. (34 - 36 kg).

At no time during installation of belt, should the belt tension exceed 160 lbs (73 kg).

At the time of installation, the belt must not be rolled over the installed edges of the starter/generator or drive clutch pulleys. Excessive stretch in belt may cause cord failure.

A loose belt can cause audible vibration and squeal.

Tighten a new starter/generator belt to 110 - 130 lbs. (50 - 59 kg) tension when a gauge is applied half way between the two pulleys.

A new belt may be checked manually. A maximum deflection of 3/8" (10 mm) is acceptable. Tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the same technique and inspect for cracking or wear. A maximum deflection of 1/2" (13 mm) is acceptable.

NOTICE

3/8" (1 cm) MaximumDeflection (New Belt)

1/2" (1.3 cm) MaximumDeflection (Existing Belt)

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Adjusting The BeltLoosen the starter/generator pivot bolt. While holding the lower adjusting nut with a wrench, loosen the upper jam nut with another wrench. Move the lower nut up or down the adjustment bolt until proper belt tension is achieved. Hold the lower nut in place and tighten the upper jam nut against it. Tighten the starter/generator pivot bolt.

BATTERY CLEANING

To reduce the possibility of damage to vehicle or floor, neutralize acid before rinsing battery.To reduce the possibility of damage to electrical components while cleaning, do not use a pressure washer.Cleaning should take place per the Periodic Service Schedule.When cleaning the outside of the battery and terminals, first spray with a solution of sodium bicarbonate (baking soda) and water to neutralize any acid deposits before rinsing with clear water.Use of a water hose without first neutralizing any acid, will move acid from the top of the battery to another area of the vehicle or storage facility where it will attack the metal structure or the concrete/asphalt floor. Additionally, a resi-due will be left on the battery which is conductive and will contribute to the discharge of the battery.

To reduce the possibility of battery explosion that could result in severe injury or death, do not use metallic spray wand to clean battery and keep all smoking materials, open flame or sparks away from the battery.The correct cleaning technique is to spray the top and sides of the battery with a solution of sodium bicarbonate (baking soda) and water. This solution is best applied with a plastic spray bottle. The solution should consist of the 2 teaspoons (10 ml) of sodium bicarbonate (baking soda) and 1 quart (1 liter) clear water as shown. In addition to the battery, special attention should be paid to metal components adjacent to the battery which should also be sprayed with the sodium bicarbonate (baking soda) solution. Allow the solution to sit for at least three minutes; use a soft bristle brush or cloth to wipe the tops of the battery to remove any residue that could contribute to the self discharge of the battery. Rinse the entire area with low pressure clear water. Do not use a pressure washer.

1 quart(1 liter)

Clear Water

2 Teaspoons(10 ml)Sodium

Bicarbonate(Baking Soda)

PlasticSprayBottle

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BRAKES

To reduce the possibility of severe injury or death, always evaluate pedal travel before operating a vehicle to verify some braking function is present.All driving brake tests must be done in a safe location with regard for the safety of all personnel.

Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.

The Periodic Brake Performance Test should be performed regularly as an evaluation of braking system perfor-mance. It is useful as a method of identifying subtle loss of performance over time.

Periodic Brake Test For Mechanical Brakes

The purpose of this test is to compare the braking performance of the vehicle to the braking performance of new or ‘known to be good’ vehicles or to an established acceptable stopping distance. Actual stopping distances will be influenced by weather conditions, terrain, road surface condition, actual vehicle weight (accessories installed) and vehicle speed. No specific braking distance can be reliably specified. The test is conducted by latching the park brake to eliminate different pedal pressures and to include the affects of linkage mis-adjustment.

Establish the acceptable stopping distance by testing a new or ‘known to be good’ vehicle and recording the stopping location or stopping distance. For fleets of vehicles, several vehicles should be tested when new and the range of stopping locations or distances recorded.

Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.

Drive the vehicle at maximum speed on a flat, dry, clean, paved surface. Quickly depress the brake pedal to latch the parking brake at the line or marker in the test area and remove foot from pedal. The vehicle should stop aggres-

NOTICE

LatchParking Brakeand Take FootOff Pedal

Line or Marker

AcceptableStoppingDistance

Normal Range of Stopping Distance

Any vehicles that stop more than 4 ft. (1.2 m) beyond the Acceptable Stopping Distance or pulls to one side should be removed from service and inspected by a qualified mechanic

Accelerate ToMaximum Speed

4 ft. (1.2 m)

Line or Marker

Dry, Level, Clean, Paved Surface

NOTICE

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sively. The wheel brakes may or may not lock. Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched. The vehicle should stop within the ‘normal’ range of stop-ping distances. If the vehicle stops more than 4 ft. (1.2 m) beyond the acceptable stopping distance or pulls to one side, the vehicle has failed the test and should be tested again.If the vehicle fails the second test, it should immediately be removed from service. The vehicle must be inspected by a qualified mechanic who should refer to the TROUBLESHOOTING section in the Technician’s Repair and Ser-vice Manual.

AIR INTAKE AND COOLING FINS

To prevent possible burns, engine parts should be kept clean to reduce risk of overheating and ignition of accumulated debris. After every off road use, allow to cool and then check for a build up of dirt and debris in the air intake and cooling fins. Dirt and debris may clog the engine’s air cooling system. Clean areas shown to prevent engine damage. Keep linkages, springs and con-trols clean. Keep area around muffler free of any combustible material.At least once a year, (or more often under adverse conditions) the cooling system should be cleaned. Cleaning will assure an adequate supply of air to the cooling fins. Compressed air may be used for routine cooling system mainte-nance.

REAR AXLEThe rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing. Unless leakage of rear axle lubricant is evident, an annual lubricant check is sufficient.

Checking The Lubricant LevelTool List Qty. Socket, 13 mm, 3/8" drive....................................................................................................................................... 1Ratchet, 3/8" drive .................................................................................................................................................. 1Funnel..................................................................................................................................................................... 1

For vehicles with LSD axle, add 2 ounces of friction modifier during refill.

Clean the area around the check and fill plugs. Remove the check plug. The correct lubricant level is just below the bottom of the threaded hole. If lubricant is to be added, remove the fill plug and add lubricant using a funnel. Add lubricant slowly until lubricant starts to seep from the check plug hole. Install the check plug and the fill plug. In the event that the lubricant is to be replaced, a drain plug is provided at the bottom of the differential housing.

NOTICE

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AIR CLEANER INSPECTION AND REPLACEMENTThe air cleaner unit on the vehicle is a dry unit. Do not use oil on the filter element or any part of the unit. To aide instal-lation and sealing, petroleum jelly may be applied to back side of cover tabs and each side of filter seal.

Cleaning the Air Filter Element

Do not use compressed air to clean the air filter; doing so will damage the filter which may result in damage to the engine.

The air cleaner element is accessible by unsnapping the clips on the air canister and removing the cover and air filter element. Clean inside of cover, canister and dust collector. Install the element and cover the same way they were removed. Be sure the positioning arrow on cover is pointing upward and all clips are fastened securely.

If the element is in acceptable condition, loose dirt may be removed by tapping the filter lightly. Do not use oil on the fil-ter element or any part of the unit.

Drain Plug

Fill / Check Plug

Dust Collector

Air Cleaner Cover

Air Cleaner Canister

Air Filter Element

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LUBRICATION

Do not use more than three (3) pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components.

Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure.

SPARK PLUGSTool List Qty.Spark plug socket, 13/16", 1/2" drive ...................................................................................................................... 1Ratchet, 1/2" drive .................................................................................................................................................. 1Plug gauge, wire type ............................................................................................................................................. 1Anti-seize compound ........................................................................................................................................... ARTorque wrench, 1/2" drive, ft. lbs............................................................................................................................. 1

Use care not to over-tighten the plug. Over-tightening can cause damage to the aluminum cylinder head threads.

Remove and inspect the spark plug at intervals indicated in the Periodic Service Schedule. Spark plug should be properly gapped. Tighten to 16 ft. lbs. (22 Nm) torque

Lubrication Points

View from Underside of Vehicle

RackBallJoint

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Remove and inspect the spark plug at intervals indicated in the Periodic Service Schedule. Spark plug should be prop-erly gapped. Tighten to 16 ft. lbs. (22 Nm) torque.Fouled spark plug is indicated by a wet, black appearance. This could be caused by a dirty air filter element or other restrictions in the air intake system. Incorrectly adjusted valves, spark plug wire which are in poor condition or poor quality fuel could also contribute to the problem.

PROLONGED STORAGE

To reduce the possibility of severe injury or death resulting from a possible explosion:Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark.Store vehicle in a clean, dry area. Do not store in same area as a stove, furnace, water heat-er, or other appliance that uses a pilot light or has a device that can create a spark.When refueling, inspect the fuel cap for leaks or breaks that could result in fuel spillage.Always wear safety glasses while refueling to prevent possible eye injury from gasoline or gasoline vapor.Keep hands, clothing and jewelry away from moving parts. Use care not to contact hot objects. Raise the rear of the vehicle and support on jack stands before attempting to run the engine.

Preparing the engine for a prolonged storage period (30 days or more) calls for a few simple steps to prevent a build up of varnish and gum in the carburetor and corrosion in the engine.

• Turn the Key Switch to OFF position, and leave the Forward/Reverse switch in the NEUTRAL position during storage.

• Perform all required routine maintenance per the Periodic Service Schedule.

• Properly inflate the tires to recommended pressure (psi) stated on sidewall of tires.

• Place the Forward/Reverse handle in the NEUTRAL position engage the neutral lock, see page 5 - 11.

• Turn the fuel shut-off valve to the closed (OFF) position.

• With proper ventilation, run engine until the remaining fuel in carburetor and fuel lines is depleted and the engine stalls.

• Return the neutral lock to the OPERATE position

• Loosen, but do not remove the carburetor drain screw. Drain any fuel remaining in bowl into an approved container and pour the fuel collected into the vehicle fuel tank. Add Sea Foam (4 oz. for a full tank of fuel) to stabilize fuel and install the tank cap securely.

• Tighten the carburetor drain screw.

.030"(.75 mm)

Gap

Spark Plug

Fuel Shut-off ValveTurn to “OFF” Position

5 - 23


5

• Remove spark plug and pour about 1/2 oz. (15 ml) of SAE 10 - 30 weight oil or Fogging oil into the cylinder. Rotate the crankshaft by hand several times, then install the spark plug.

• Do not engage the park brake, but secure the car from rolling

• While engine is still warm, change oil.

• Clean body, chassis and engine of debris, mud, chaff or grass.

5 - 24


5

PERIODIC SERVICE SCHEDULE

Check Clean, Adjust, etc. ReplaceTo perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see

the Repair and Service Manual for this vehicle.NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions

DAILYBEFORE USE: Check service brake general operation Check park brake operation - does it hold on a hill. Check warning device function in reverse Check tire pressure, condition of tires & rims. Check smooth operation of accelerator. Check for loose or missing hardware. Check Battery - state of charge, condition, loose terminals, corrosion, hold down &

hardware Check overall vehicle condition

WEEKLY (includes items listed in previous table & the following)

TIRES Examine for cuts, excessive wear and pressure (See GENERAL SPECIFICA-TIONS)

WHEELS Check for bent rims, missing or loose lug nutsCOOLING FAN Check for build-up of foreign matter inside blower housing and fins, clean if requiredENGINE OIL Check and add if required - DO NOT OVERFILLSTARTER/GENERATOR BELT Check for tension, wear, cracks

MONTHLY - 20 HOURS (includes items listed in previous table & the following) WIRING Check all wiring for loose connections and broken/missing insulationACCELERATOR Check for smooth movement - DO NOT LUBRICATE CABLESERVICE BRAKE

(MECHANICAL BRAKES) Conduct brake performance test

PARK BRAKE Check brake performance and adjust if requiredCHOKE CABLE Check for smooth movement and adjustment - DO NOT LUBRICATE CABLECARBURETOR LINKAGE Check attachment, adjust as requiredDIRECTION SELECTOR Check attachment, adjust as requiredENGINE Check for unusual noise, vibration, acceleration, oil leaksCOOLING FAN Check for build-up of foreign matter inside blower housing and fins, clean if requiredSTEERING ASSEMBLY Check for abnormal play, tightness of all hardwareTIE ROD/LINKAGES Check for excessive play, bent components or loose connectionsREAR AXLE Check for leakage, add SAE 30 oil as required

QUARTERLY - 60 HOURS (includes items listed in previous tables & the following)

FRONT AXLE Check for damage to axle and loose or missing hardware

FRONT SHOCK ABSORBERS Check for oil leakage and loose fastenersFRONT SPRINGS Check for loose hardware, cracks at attachmentsFRONT WHEEL ALIGNMENT Check for unusual tire wear, align if required

PARK BRAKE

Check for bent/binding linkage rod Check for damage or wear to latch arm or catch bracket Lubricate as required, use light oil. DO NOT LUBRICATE CABLES OR BRAKE

LATCHREAR SHOCK ABSORBERS Check for oil leakage, loose mounting hardwareENGINE ELECTRICAL SYSTEM Check coil/spark plug wires for cracks/loose connections

Periodic Service Schedule

5 - 25


5

5

FUEL SYSTEMCheck for leaks at tank, cap, system lines, filters, pump, carburetorCheck system lines for cracks/deterioration

THROTTLE/GOVERNOR LINKAGE Check operation and governed speed

HARDWARE AND FASTENERSCheck for loose or missing hardware and components Tighten or replace missing hardware

SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)BATTERY Clean battery & terminalsDIRECTION SELECTOR Check for wear and smooth movement (lubricate shaft with light oil if required)KING PINS Check for excessive play and tightness of retaining nutsSTEERING ASSEMBLY Check bellows and pinion seal for damage or grease leakageRACK END BALL JOINT Lubricate, use wheel bearing greaseREAR AXLE Check for unusual noise and loose or missing mounting hardwareAIR FILTER ELEMENT Check filter element, clean/replace as requiredOIL FILTER Replace (at oil change)

ENGINE OIL Replace with SAE 10W-30 or 10W-40 that meets or exceeds SF, SG, CC oil, DO NOT OVERFILL

DRIVE BELT Check for cracks, fraying and excessive wear

ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)FRONT WHEEL BEARINGS Check and adjust as required, see Technician’s Repair and Service ManualREAR AXLE Check lubricant, add lubricant as required

SERVICE BRAKESClean and adjust, see Technician’s Repair and Service ManualCheck brake shoe linings, see Technician’s Repair and Service ManualCheck level, add if required (DOT 3) and check for leakage

FUEL FILTER ReplaceSPARK PLUG Replace, gap new plugMUFFLER/EXHAUST Check mounting hardware; check for leaks at head and muffler gasketsVALVES Check cold (intake/exhaust) per Technician’s Repair and Service Manual

500 HOURS (includes items listed in previous tables & the following)CARBURETOR Clean

CYLINDER HEAD AND PISTON Remove carbon from cylinder head and piston Check valve seats for carbon buildup and clean as required

Periodic Service Schedule

- 26

5 - 27


5

CAPACITIES AND REPLACEMENT PARTS

HARDWAREPeriodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table.Use care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific torque values.Generally, three grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head. Unmarked hardware is Grade 2.

Fuel Tank / Fuel

Engine Oil

Oil Filter

Air Filter

Spark Plug

Starter/Generator Belt

Clutch Belt

Rear Axle Oil

Fuse

LED Bulb

Headlight Bulb

Turn Signal Bulb

6.0 gal (22.5 liters) / 87 Octane Min.

1.4 US qt (1.3 liters)

51 oz (1.5 liters) / SAE 30

2 oz (60 mL) (P/N 625753)

15 amp (P/N 18392-G1)

(P/N 619101)

(P/N 619100)

(P/N 619102)

P/N 26591-G01

P/N 28463-G01

NGK BPR2ES (P/N 25523-G3)

.020 - .030" (.71 - .75 mm) Gap

P/N 606138

P/N 606136

#1157 (P/N 21759-G1)Tail Light Bulb

Friction Modifier (Rear Axle)

ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)

BOLT SIZE

Grade 2

1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"

Unless otherwise noted in text, tighten all hardware in accordance with this chart.This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when

installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.

4(5)

8(11)

15(20)

24(33)

35(47)

55(75)

75(102)

130(176)

125(169)

190(258)

Grade 5

Grade 8

6(8)

13(18)

23(31)

35(47)

55(75)

80(108)

110(149)

200(271)

320(434)

480(651)

6(8)

18(24)

35(47)

55(75)

80(108)

110(149)

170(230)

280(380)

460(624)

680(922)

BOLT SIZE

Class 5.8(Grade 2)

M4 M5 M6 M8 M10 M12 M141

(2)2

(3)4

(6)10

(14)20

(27)35

(47)55

(76.4)

Class 8.8(Grade 5)

2(3)

4(6)

7(10)

18(24)

35(47)

61(83)

97(131)

Class 10.9(Grade 8)

3(4)

6(8)

10(14)

25(34)

49(66)

86(117)

136(184)

5.8

8.8

10.9

5 - 28


Notes:

5

APPENDIX ARead all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

TABLE OF CONTENTS FOR APPENDIX A

TITLE PAGE NO.

DECLARATION OF CONFORMITY .................................................................................................................................................................A - 3

A - 1


Notes:

A - 2


DECLARATION OF CONFORMITY

A - 3


DECLARATION OF CONFORMITY (CONTINUED)

A - 4

Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

APPENDIX A

Notes:

A - 5


Notes:

A - 6

Copyrighted MaterialThis manual may not be reproduced in whole or

in part without the express permission ofE-Z-GO Division of Textron Inc.

Technical Communications Department

E-Z-GO Division of Textron Inc.,1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA

Service Parts Manuals, as well as Repair and Service Manualsare available from a local Distributor, an authorized Branch,Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.

Documents

Owner’s Guide€¦ · WELCOME Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Guide. This guide contains